Seam-in-pad apparatus with cycling shorts application

ABSTRACT

A pad for use in clothing garments bonds to a garment seam to provide protection from chafing or irritation caused by the seam and provide support and strength to the seam. The seam may be embedded within the pad to integrate the seam into the padding to eliminate contact between the wearer&#39;s body and the seam stitching. The seam may be bonded to or embedded within the pad during manufacture of the pad or in a separate step using preformed pads and seams.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit of and priority to U.S.Provisional Application Ser. No. 62/669,476, filed on May 10, 2018 theentire contents of which are incorporated herein by reference.

BACKGROUND 1. Technical Field

The technical field relates generally to pads with embedded seams to beused in the manufacture of clothing. In particular, the invention refersto cycling shorts incorporating two pads with embedded seams wherein theseams and pads rest under the perineal bones of the wearer.

2. Background of the Related Art

The juncture of two pieces of material, known generally as a seam,whether it be through stitching, glue, or any other means, alters theproperties of the materials it joins. Elastic materials, such as rubber,will generally lose some elasticity when joined. Soft materials, such assilk, will generally feel rougher around the seam. When a manufacturerwants to put comfort above all else in their garment, the garments'seams are the areas of most concern. A need exists for a method ofjoining materials to eliminate or reduce the discomfort caused by seams.One segment of the populace which feels this need all too keenly arecyclists.

Cycling shorts incorporating a pad for comfort are ubiquitous in in thecycling community. The bicycle seat or saddle puts a large amount ofpressure on the perineal or ischiatic parts of the body and can subjectthe cyclist to pain during intensive use. Pads located on or around theperineum are therefore necessary to enhance rider comfort andperformance.

Current art, such as U.S. Pat. No. 9,526,277 B2 among others, describe alarge pad which sits across the entire pelvic area. Such pads shall nowbe referred to as “chamois pads.” Chamois pads suffer from manydeficiencies. One such deficiency is a lack of tactical stretch. Thingarments worn by today's athletes have the ability to expand andcontract according to an athlete's movement. This elasticity savesenergy because the athlete does not have to battle through theresistance of restrictive clothing. Such elasticity is most necessary inthe most dynamic parts of the body. The pelvic area is constantly influx when cycling as the cyclist churns their legs and shifts theirweight on the saddle. Chamois pads have little tactical stretch toaccommodate this movement and therefore cause the cyclist to expend moreenergy.

Chamois pads suffer from an excess of material which leads to poorthermodynamic and aerodynamic properties. The thicker the material anathlete wears, the more difficult it is to dissipate heat through thatmaterial. Such heat retention can negatively impact performance. Thickchamois pads also increase surface area and drag which negatively impactperformance.

Chamois pads suffer from an imperfect pressure gradient. Chamois padsspread pressure imparted from the saddle across its entire surface.Ideally, pressure should be directed away from tender areas in themiddle of the cyclists' perineal region and onto the skeleton where itcan more comfortably be endured.

Current art attaches the chamois pad to the fabric either by directstitching or placing the chamois pad in a sown-in pocket. Directlystitched chamois pads suffer from similar drawbacks of tactical stretchand pelvic discomfort as described above. Sown-in pockets leave room forthe chamois pad to shift and move when cycling which is not preferred.Both methods have shortcomings which can be addressed.

Current art in the field of athletic shorts or trousers describe a seamrunning through the middle of the garment under the perineal region.From here on such a seam shall be referred to as a “center seam.” Centerseams have specific deficiencies for cyclists. One such deficiency, asnoted above, is a lack of tactical stretch. Flexibility of the garmentalong the direction of the seam is limited. For example, the garment hasless ability to flex along its backside as the cyclist shifts between anupright and a forward position.

A center seam also causes discomfort. Male cyclists especially, but notsolely, can experience distress in particularly tender areas of theperineum from rubbing contact with the seam. Center seams also tend tocause an uncomfortable bunching and tightening of material between thebuttocks; more commonly referred to as a “wedgie.” For female cyclists,this effect occurs on the front of their pelvic region, causing physicaldiscomfort and drawing unwanted attention to that region. For malecyclists, male genitals will often rest on one side of the seam. Thiscan cause a misalignment of the shorts and further discomfort.

Current art describes athletic garments of this variety with only asingle layer of fabric. This fabric must balance the requirements offlexibility (to increase performance) and strength (to increaselongevity and appearance). Different parts of the garment prioritizedifferent concerns. For example, the groin area of the garment wouldbenefit from higher flexibility, while the backside of the garment wouldbenefit from higher strength. The addition of another layer of materialwould allow for a separation of functions and thereby create a moreoptimized athletic garment.

SUMMARY OF THE INVENTION

The deficiencies in the prior art are overcome or alleviated by thetechnology described below. Generally, one embodiment describes a seambonded to the inside of a compliant pad. This technique reducesdiscomfort caused by fabric seams in contact with a wearer.Specifically, embodiments of this technology describe a cycling garmentcomprising two separate pads with the structural seams of the garmentembedded in the pads. This provides cushioning and avoids the discomfortassociated from a seam trapped between a hard cycling saddle and thewearer's pelvic bones. The two-pad design is an improvement on the moretraditional chamois pad by increasing tactical stretch and removingunnecessary material. The seams and pads are located under the ischialbones of the wearer, leaving the middle of the garment seamless to allowfor maximum comfort and performance. The pads and seams are interposedbetween two layers of fabric to optimize functionality, comfort, andperformance.

The above-discussed and other features and advantages of the garment andits method of manufacture will be appreciated and understood by thoseskilled in the art from the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures illustrate one or more embodiments of thedisclosed seam-in-pad apparatus with cycling shorts being one possibleapplication. These figures, together with the detailed description,serve to explain the aspects and implementations of the apparatus andits applications. Embodiments are described in conjunction with theappended figures.

FIG. 1 shows a cross sectional view of a pad with an embedded seam andtwo pieces of connecting fabric.

FIG. 2 shows an isometric view of one shape the pads may form.

FIG. 3 shows, in relation to a typical pair of shorts, where the padscould lie.

FIG. 4 shows one embodiment of the garment.

FIG. 5 shows another embodiment of the garment including wing sections.

FIG. 6 shows another embodiment of the garment including a back section.

FIG. 7 shows an upward, front-facing view of one embodiment of thegarment worn inside-out.

FIG. 8 shows one embodiment of the garment.

FIG. 9 shows a cross sectional view of one embodiment of the garment.

While embodiments of the disclosure are amenable to variousmodifications and alternative forms, specific embodiments have beenshown by way of example in the drawings and are described in detailbelow. The intention, however, is not to limit the scope of thedisclosure to the particular embodiments described. On the contrary, thedisclosure is intended to cover all modifications, equivalents, andalternatives falling with the scope of the disclosure and the appendedclaims.

DETAILED DESCRIPTION

All illustrations of the drawings are for describing selectedembodiments and are not intended to limit the scope of the claims. Thefollowing specification describes a seam-in-pad apparatus as applied toa cycling garment. However, the inventive seam-in-pad design may be usedin any application in which a seam, stitch or other joint may benefitfrom or require cushioning or padding.

The seam-in-pad apparatus 100 comprises at least a pad 101, a seam 103,and at least two pieces of fabric-like material 105 a, 105 b as depictedin FIG. 1. The pad 101 may be made from any kind of polymer, such asrubber, silicone, or the like. A non-exhaustive list of possiblematerials includes: polydimethylsiloxanes (and other siloxane compoundswith biocompatibility), dimethylamylmines, polypropylenes,polyurethanes, polyacetals, polysulfones, polycarbonates, polystyrene,polyamides, poly(N-vinyl pyrrolidone), and polyethylene terephthalate.In one embodiment, the pad 101 material is created with certain desiredproperties in mind, such as flexibility, hardness, comfort, andstrength. The seam 103 may be stitched in any number of ways such as achain stitch, lock stitch, zigzag stich, and the like. The preferredembodiment utilizes a four-thread overlock stitch to promote tensilestrength and a strong bond between the pad 101 and seam 103. The fabric105 a, 105 b may be made from wool, cotton, silk, leather, or any numberof materials. One piece of fabric 105 a may be made of the same ordifferent material as the other piece of fabric 105 b.

The pad 101 may be manufactured by molds (pour over molds, liquidinjection molds, etc.), by direct fabrication techniques, by 3Dprinting, or other means. The seam 103 may be bonded to the pad 101 byany number of means. In one embodiment, the two pieces of fabric 105 a,105 b are first stitched together to create the seam 103. The seam 103is then embedded into the pad 101. If a pour-over mold is used to createthe pad 101, then the seam 103 may be dipped into the still hardeningpad 101 material. The pad 101 material seeps into or impregnates theseam 103. Wax paper, hangars, hooks, or other means to separate thefabric 105 a, 105 b from the pad 101 and to keep the seam 103 suspendedat the preferred location in the pad 101 material may be used. If aliquid injection mold is used to create the pad 101, then a means ofsuspending the seam 103 inside the mold can easily be imagined. In thisembodiment, if the pad 101 is manufactured by a direct fabricationtechnique, then the seam 103 may be suspended into the pad 101 while thepad 101 material is still hardening, post fabrication. The seam 103 mayalso be incorporated into the manufacturing technique to form the pad101. The pad 101 may also be manufactured with a slit in the materialfor which the seam 103 may be pushed into.

The seam-in-pad apparatus 100 may be used for a number of applicationswhere one is looking to avoid the discomfort of a seam and/or an impactabsorbing and vibrational damping pad is needed. In one embodiment, theseam-in-pad apparatus 100 is used to create a cycling garment(“garment”) 210 as seen in FIG. 2-9. There may be any number ofseam-in-pad apparatuses 100 in the garment 210.

The pads 101 may take any number of shapes. In one embodiment, there aretwo pads 201 a, 201 b that sit directly under the ischial bones of thewearer. The general location of these pads 201 a, 201 b can be seen inFIG. 3. In one embodiment, as seen in FIG. 2, the pads 201 a, 201 b areshaped to trace the contours of the ischial bones. This allows for aminimal amount of pad 201 material, which increases airflow andthermodynamic properties of the garment 210. In one embodiment the pad201 thickness and/or width taper from large posteriorly to smallanteriorly. The exact dimensions of the pad 201 may depend upon aspecific cyclist's pelvic dimensions as well as the dimensions of theirpreferred cycling saddle. Rapid customization of these pads 201 a, 201 band garment 210 is made easier with the recent advances in 3D printing.

In one embodiment, as seen in FIG. 4, the garment 210 comprises pads 201a, 201 b, seams 203 a, 203 b, and a center section 207. In oneembodiment the seams 203 a, 203 b are embedded in the pads 201 a, 201 bas described above. In one embodiment, the pads 201 a, 201 b situnderneath the ischial bones and the center section 207 lies underneaththe mid-sagittal plane 350, as seen in FIG. 10, of the cyclist. Thelocation of the seams 203 a, 203 b lateral to the mid-sagittal plane 350allows the cyclists genitals to rest in the elastic pocket created bythe center section 207 increasing comfort for the rider. In oneembodiment, the center section 207 is made of a separate material to therest of the garment 210. This material may be tailored to fit themanufacturer's particular interest in that area. Since the centersection 207 covers a particularly delicate area, it can be imagined thatcomfort would be the highest priority. It can be imagined that materialaround the outside of the garment 210 described above and seen in FIG. 4can be stitched at the seams 203 a, 203 b, as well as other placesnecessary, in order to make a garment suitable for cycling.

In one embodiment, as seen in FIG. 5, the garment 210 comprises pads 201a, 201 b, seams 203 a, 203 b, a center section 207, and one or more wingsections 209 a, 209 b situated lateral to the pads 201 a, 201 brespectively. In one embodiment, the wing sections 209 a, 209 b are madeof a separate material to the rest of the garment 210. This material maybe tailored to fit the manufacturer's particular interest in that area.Since the wing sections 209 a, 209 b cover a very mobile part of thecyclist (between the inner thigh and pelvis) it can be imagined thatelasticity would be the highest priority. It can be imagined thatmaterial around the outside of the garment 210 described above and inFIG. 5 can be stitched in order to make a garment suitable for cycling.

In one embodiment, as seen in FIG. 6, the garment 210 comprises pads 201a, 201 b, seams 203 a, 203 b, a center section 207, one or more wingsections 209 a, 209 b, and a back section 211. In one embodiment, theback section 211 is made of a separate material to the rest of thegarment 210. This material may be tailored to fit the manufacturer'sparticular interest in that area. Since the back section 211 covers anarea more likely to tear than other areas (across the backside) it canbe imagined that strength would be the highest priority. It can beimagined that material around the outside of the garment 210 describedabove and in FIG. 6 can be stitched in order to make a garment suitablefor cycling.

One depiction of the garment 210 described above can be seen in FIG. 7.This would be one embodiment of the invention if worn by a cyclistinside out from an upward front facing perspective. Depicted in thefigure are the two seams 203 a, 203 b between the center section 207 andthe two wing sections 209 a, 209 b. It should be noted that the seams203 a, 203 b and the wing sections 209 a, 209 b are mirrored versions ofprevious figures. This is due to a reverse perspective. In FIG. 4-6 thegarment 210 is back facing. In FIG. 7 the garment 210 is front facing.The garment 210 looks inside out due to the lack of pads 201 a, 201 bshown in the figure. It appears that the pads 201 a, 201 b are on theinside of the garment 210 in contact with the wearer. In the preferredembodiment the pads 201 a, 201 b would be on the outside of thisembodiment of the garment 210 to maximize comfort.

FIG. 8 shows another back facing perspective of the garment 210 with allelements in view.

In one embodiment, as seen in FIG. 9, the garment 210 comprises pads 201a, 201 b, seams 203 a, 203 b, a center section 207, one or more wingsections 209 a, 209 b, and an outer section 213. In one embodiment, theouter section 213 is made of a separate material to the rest of thegarment 210. This material may be tailored to fit the manufacturer'sparticular interest in that area. Since the outer section 213 covers anarea more likely to tear than other areas (across the backside) it canbe imagined that strength would be the highest priority.

The outer section 213 surrounds the pads 201 a, 201 b to effectivelycreate three layers. There is the inner layer comprising the hiddenseams 203 a, 203 b, the center section 207, and the wing sections 209 a,209 b that make contact with the wearer. There is the middle layercomprising the pads 201 a, 201 b. And there is the outer layercomprising the outer section 213. One of the many benefits of havingthese separate layers is to compartmentalize material to fit specificpurposes of the garment. The inner section can be softer to increasecomfort and more flexible to increase performance. The outer garment canbe stronger to increase durability. The dual layers also have aestheticappeal. If the garment would become wedged in an uncomfortable area ofthe pelvis (such as wedgies, camel-toe, etc.), such a situation will notbe visible to the public because the existence of an outer layer wouldcover up those displays.

This technology is not limited to cycling gear and can be applied to anynumber of other applications. One possible application includes anysupplemental protective pad or alternative pad design which providesprotection for the pelvic area. A number of possible applications areassociated with sporting activities such as: athletic cups, sports bras,combat shorts (boxing, kick-boxing, Ultimate Fighting Championship),rowing seats, padding for the hip or femur bones for activities such asbiking, roller skating, ice skating, skateboarding, or the like, androck climbing harness pads (for interfaces between the harness and therock climber). A number of possible applications are associated withmedical devices such as skin-device interfaces for prosthetic limbs, andmedical recovery garments/devices for burns, hemorrhoids, surgery,giving birth, road rash, compression, icing, or warming.

What is claimed is:
 1. A cycling garment comprising: a pad; and at leasttwo fabric sections joined at a seam, at least a portion of the seambeing bonded to the pad.
 2. The cycling garment of claim 1, wherein thepad is comprised of a polymer material.
 3. The cycling garment of claim2, wherein the polymer is silicone.
 4. The cycling garment of claim 2,wherein the polymer is rubber.
 5. A cycling garment comprising: a firstfabric section; a second fabric section joined to the first fabricsection to form a first seam; and a first pad disposed along the firstseam, at least a portion of the first seam bonded to the first pad. 6.The garment according to claim 5 further comprising: a third fabricsection joined to the first fabric section to form a second seam; and asecond pad disposed along the second seam, at least a portion of thesecond seam bonded to the second pad.
 7. The garment according to claim6 further comprising a back fabric section attached to a posterior of atleast the first fabric section.
 8. The garment according to claim 6further comprising a front fabric section attached to an anterior of atleast the first fabric section.
 9. The garment according to claim 6further comprising an outer fabric section attached to the cyclinggarment so as to dispose at least the first pad between the firstsection and the outer section.
 10. The garment of claim 5 wherein thefirst pad is positioned lateral to a mid-sagittal plane in a firstdirection.
 11. The garment according to claim 5, wherein at least aportion of the first pad is positioned beneath an ischial pelvis bone ofa person wearing the garment.
 12. The garment according to claim 6wherein the first pad is positioned lateral to a mid-sagittal plane in afirst direction and the second pad is positioned lateral to themid-sagittal plane in in a second direction.
 13. The garment accordingto claim 12, wherein at least a portion of the first pad is positionedbeneath a first ischial pelvis bone of a person wearing the garment andthe second pad is positioned beneath a second ischial pelvis bone of aperson wearing the garment.
 14. A method for manufacturing a cyclinggarment comprising at least the steps of: providing a first fabricsection; providing a second fabric section; providing a first pad;joining the first and second fabric sections to form a first seam;bonding the first seam to the inside of the first pad;
 15. The method ofclaim 14 wherein the step of bonding the first seam into the first padcomprises the steps of: positioning at least a portion of the first seamwithin a pad mold; filling the pad mold with a pad material; and curingthe pad material to bond the at least a portion of the first seam to thefirst pad.
 16. The method of claim 14 further comprising providing athird fabric section; providing a second pad; joining the first andthird fabric sections to form a second seam; bonding the second seam tothe inside of the second pad.
 17. The method of claim 14 furthercomprising attaching a back fabric section to a posterior of at leastthe first fabric section.
 18. The method of claim 14 further comprisingattaching a front fabric section to an anterior of at least the firstfabric section.
 19. The method of claim 14 further comprising attachingan outer fabric layer to the cycling garment so as to dispose the firstpad between the at least first fabric section and the outer fabriclayer.
 20. The method of claim 16 wherein the first and second pads arepositioned to rest directly under the wearer's ischial pelvis bones.